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contact area. Molds may be either solid "massive" design, sand cast (e.g. for pig iron), or water-cooled shells, depending upon heat transfer requirements. Ingot molds are tapered to prevent the formation of cracks due to uneven cooling. A crack or void formation occurs as the liquid to solid transition has an associated volume change for a constant mass of material. The formation of these ingot defects may render the cast ingot useless and may need to be re-melted, recycled, or discarded.
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A variety of designs exist for the mold, which may be selected to suit the physical properties of the liquid melt and the solidification process. Molds may exist in the top, horizontal or bottom-up pouring and may be fluted or flat walled. The fluted design increases heat transfer owing to a larger
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For a top-poured ingot, as the liquid cools within the mold, differential volume effects cause the top of the liquid to recede leaving a curved surface at the mold top which may eventually be required to be machined from the ingot. The mold cooling effect creates an advancing solidification front,
251:, and a liquid region. The rate of front advancement controls the time that dendrites or nuclei have to form in the solidification region. The width of the mushy zone in an alloy may be controlled by tuning the heat transfer properties of the mold or adjusting the liquid melt alloy compositions.
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The physical structure of a crystalline material is largely determined by the method of cooling and precipitation of the molten metal. During the pouring process, metal in contact with the ingot walls rapidly cools and forms either a columnar structure or possibly a "chill zone" of equiaxed
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Secondly, the shape and size of the mold is designed to allow for ease of ingot handling and downstream processing. Finally, the mold is designed to minimize melt wastage and aid ejection of the ingot, as losing either melt or ingot increases manufacturing costs of finished products.
74:. Ingots usually require a second procedure of shaping, such as cold/hot working, cutting, or milling to produce a useful final product. Non-metallic and semiconductor materials prepared in bulk form may also be referred to as ingots, particularly when cast by mold based methods.
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Single crystal ingots of metal are produced in similar fashion to that used to produce high purity semiconductor ingots, i.e. by vacuum induction refining. Single crystal ingots of engineering metals are of interest due to their very high strength due to lack of
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In the United States, the brass and bronze ingot making industry started in the early 19th century. The US brass industry grew to be the number one producer by the 1850s. During colonial times the brass and bronze industries were almost non-existent because the
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which has several associated zones, closer to the wall there is a solid zone that draws heat from the solidifying melt, for alloys there may exist a "mushy" zone, which is the result of solid-liquid equilibrium regions in the alloy's
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Continuous casting methods for ingot processing also exist, whereby a stationary front of solidification is formed by the continual take-off of cooled solid material, and the addition of a molten liquid to the casting process.
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Ingots are manufactured by the cooling of a molten liquid (known as the melt) in a mold. The manufacture of ingots has several aims.
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required for later processing, as the structure formed by the cooling of the melt controls the physical properties of the material.
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demanded all copper ore be sent to
Britain for processing. Copper based alloy ingots weighed approximately 20 pounds (9.1 kg).
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ingots can be used as currency (with or without being processed into other shapes), or as a currency reserve, as with
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are widely distributed archaeological artifacts which are studied to provide information on the history of
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A special case are polycrystalline or single crystal ingots made by pulling from a molten melt.
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process, which reduces cracking. A total of 5 percent of ingots must be scrapped because of
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Firstly, the mold is designed to completely solidify and form an appropriate
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Approximately 70 percent of aluminium ingots in the U.S. are cast using the
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Ingots are generally made of metal, either pure or alloy, heated past its
439:"Simulation of Silicon Casting Process for Photovoltaic (PV) Application"
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Arthur Amos Noyes; Massachusetts
Institute of Technology (1900).
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Innovations: The
History of Brass Making in the Naugatuck Valley
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637:. Huntington, New York: Robert E. Krieger Publishing Company.
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Wu, B.; Scott, S.; Stoddard, N.; Clark, R.; Sholapurwalla, A.
310:, a form of silver and gold ingots used as currency under the
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Rock Island
Arsenal Joint Manufacturing and Technology Center
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565:. John Wiley and Sons, New York; Chapman and Hall, London.
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Taylor, Howard F; Flemings, Merton. C; Wulff, John (1959).
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The boules may be either semiconductor (e.g. electronic
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and cast into a bar or block using a mold chill method.
517:. Brass world publishing co., inc. 1905. pp. 82–
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502:. Copper.org (2010-08-25). Retrieved on 2012-02-24.
483:. Copper.org (2010-08-25). Retrieved on 2012-02-24.
514:Platers' guide: with which is combined Brass world
149:and not via simple casting. Possible uses include
145:. The method of production is via single crystal
66:into a shape suitable for further processing. In
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58:is a piece of relatively pure material, usually
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21:Kingsman: The Red Diamond § Characters
184:Crystalline structure of mold cast ingot.
493:Innovations: Overview of Recycled Copper
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30:Aluminium ingot after ejection from mold
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38:Pouring molten gold into a mold at the
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539:Review of American chemical research
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605:. December 2000. Archived from
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72:semi-finished casting products
16:Piece of relatively pure metal
1:
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70:, it is the first step among
635:Principles of Solidification
600:"Direct Chill Casting Model"
584:Müller, H. R. (Ed.) (2006).
396:, traditional Chinese ingots
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654:Introduction to Materials
652:Schlenker, B.R. (1974).
633:Chalmers, Bruce (1977).
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690:Casting (manufacturing)
464:, lesscommonmetals.com.
349:ingot from Norrhyttan,
332:Wells and Mendip Museum
588:. John Wiley and Sons.
266:and butt deformation.
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264:stress induced cracks
232:Rock Island, Illinois
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676:at Wikimedia Commons
260:direct chill casting
563:Foundry Engineering
363:Plano-convex ingots
124:Bridgeman technique
120:Czochralski process
656:. Jacaranda Press.
586:Continuous casting
498:2017-04-30 at the
479:2009-06-05 at the
460:2009-01-06 at the
330:on display at the
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135:photovoltaic cells
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672:Media related to
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546:24 February
521:24 February
170:Manufacture
131:chip wafers
68:steelmaking
684:Categories
616:2010-03-25
416:References
367:metallurgy
303:Molds for
218:Re-melted
174:See also:
105:See also:
62:, that is
405:Bar stock
400:Tin ingot
241:dendrites
80:gold bars
48:Nicaragua
571:59011811
496:Archived
477:Archived
458:Archived
384:Gold bar
373:See also
347:Pig iron
224:tin pest
147:dendrite
379:Bullion
351:Dalarna
305:Chinese
164:British
674:Ingots
641:
569:
355:Sweden
312:empire
116:boules
610:(PDF)
603:(PDF)
442:(PDF)
394:Sycee
308:sycee
289:Crete
86:Types
60:metal
56:ingot
44:Siuna
639:ISBN
567:LCCN
548:2012
523:2012
64:cast
220:tin
122:or
54:An
42:in
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